Methods and compositions involving polar monomers and multivalent cations

ABSTRACT

The present invention is directed, in part, to improved polymer compositions and processes for preparing same. Specifically, in one embodiment, there is provided a process for preparing a polymer, wherein the process comprises: providing a reaction mixture comprising a portion of at least one polar monomer and at least one multivalent cation; adding the remaining portion of the polar monomer to the reaction mixture; and polymerizing the monomer to form the polymer. In certain embodiments, the reaction mixture in the providing step comprises at least two molar equivalents or greater of the total amount of polar monomer with respect to one molar equivalent of multivalent cation.

This non-provisional application is a divisional of non-provisionalapplication Ser. No. 09/954,141 filed Sep. 17, 2001, U.S. Pat. No.6,646,086 filed Sep. 21, 2000 which claims the benefit of provisionalapplication No. 60/234,263.

The present invention relates generally to polymeric compositionscomprising polar monomers and multivalent cations. More particularly,the present invention relates to monophasic compositions comprisingpolar monomers that exhibit improved physical properties through theaddition of a multivalent cation prior to polymerization. This inventionalso relates to the use of these improved compositions as, for example,coatings, polishes, sealants, caulks, adhesives, and plastics additives.

Complexes which comprise salts of various metals added to emulsions ordispersions containing polar monomers are known in the art. Thereference article Roma-Luciow et al., “Complexes of Poly(Acrylic Acid)with Some Divalent, Trivalent and Tetravalent Metal Ions”, E. PolymerJ., 37 (2001), pp. 1741-45 (“Roma-Luciow”) discloses metal complexes ofpoly(acrylic acid) or PAA with various metal salts such as chromium,iron, aluminum, bismuth, vanadium, uranium, nickel, copper, zinc,cobalt, calcium, barium, cerium, lanthane, and neodynium. The complexesdisclosed in Roma-Luciow may be used, inter alia, as precursors in theelaboration of ceramics. The Roma-Luciow article compared andcategorized the speed of exchange of water and of the carboxyl ligandfor complexes having different metal salts.

Multivalent cations are oftentimes added to polymers or copolymerspolymerized from polar monomers to improve the physical or chemicalproperties of the composition. For example, multivalent cations may beadded after the polymer or copolymer has been formed to modify variousfunctional groups present on the polymer chain. In a polymer orcopolymer containing methacrylic acid (“MAA”), the carboxylic acid maybe fully or partially neutralized by the addition of a cation to form asalt. It is believed that the addition of a cation may form ionic bondswith the negatively charged oxygen ions within the polymer or copolymer.These ionic bonds may lead to crosslinking of the polymer or copolymerchains. In this regard, a salt formed with a divalent cation may fosteran ionic “cross-link” between the two copolymer chains. The resultingpolymeric composition may be stronger as a result of this ionic“cross-link”. However, the presence of too much cation within the systemcould destabilize the polymer latex. Further, ionic cross-links that areformed post-polymerization may require the diffusion of polymer chainsto form the ionic cross-links. This requirement generates a kineticbarrier to the ionic cross-linking and, oftentimes, may result in thefailure of the system to form the maximum number of allowablecross-links from the given amount of multivalent cations.

U.S. Pat. No. 5,149,745 issued to Owens et al. (“Owens”) discussesreacting a previously formed acid-functional polymer with a transitionalmetal compound at a temperature above the Tg of the polymer to produce acrosslinked polymer. Owens teaches that the transitional metal compoundmust be relatively insoluble in water to prevent the compound fromproducing excessively high amounts of multivalent cations in solution.High levels of multivalent cations can cause dispersions or emulsions ofacid-containing polymer to coagulate out of the emulsion or aqueousdispersion due to the multivalent cation instability of the polymer.

Multivalent cations may also be added to alter the physical or chemicalproperties of a polymer composition by providing distinct, inorganicphases within the poylymeric material. U.S. Pat. No. 5,952,420 issued toSenkus et. al. (“Senkus”) discloses pressure-sensitive adhesivepolyacrylate microparticulate composites that are obtained viasuspension polymerization of an aqueous mixture that comprises anacrylic acid ester of a nontertiary alcohol, a polar monomer, a styrenesulfonate salt, and an amount of surfactant above the critical micelleconcentration. Water insoluble, metal cations in the form of metal oxidesalts are added to the aqueous mixtures as suspension stabilizermodifiers. The resultant composite formed in Senkus comprises distinctphases of inorganic materials such as activated carbon, silica gel oralumina granules bonded together with the pressure-sensitive adhesivemicroparticulate in the mass of inorganic material. These multi-phasicor nonhomogeneous polymer-inorganic composites may exhibit a greaterwater sensitivity, water whitening, and poor film appearance which maybe disadvantageous for certain applications such as pressure sensitiveadhesives. Moreover, the composites of Senkus may fail to obtain themaximum number of cross-links from the given amount of multivalentcations.

WO 01/36505 issued to Young et. al. (“Young”) also discloses theaddition of a multivalent cation in the form of a water insoluble saltto modify the physical and chemical properties of the polymericcomposites. Young discloses suspension polymerized composites comprisedof ionomeric particulates that modify the polymer matrix that it iscompatible with to form an organic particulate-filled adhesive. LikeSenkus, the resultant polymer-inorganic composite is comprised of morethan one phase and suffers from many of the same disadvantages.

The present invention provides a polymeric composition with improvedphysical properties without adding a multivalent cation afterpolymerization. Instead, the present invention uses a multivalentcation, preferably a water soluble cation, to form a complex in situwith a portion of the polar monomer prior to and/or duringpolymerization. Further, the present invention provides a polymericcomposition with improved physical properties without the formation ofmultiple inorganic phases. It is thus surprising and unexpected that thephysical properties of polymeric compositions having polar monomers maybe improved through the addition of a soluble cation salt, typically amultivalent cation, prior to and/or during polymerization and the stagedaddition of the polar monomer. The staged addition of the polar monomerand the addition of the cation salt may create a polymer or polymerlatex with a high degree of ionic cross-linking without compromisingpolymer or polymer latex stability. Moreover, the present inventionavoids gellation and gritting problems that are oftentimes experiencedwith the addition of a multivalent cation.

The present invention is directed, in part, to improved polymercompositions and processes for preparing same. Specifically, in oneembodiment, there is provided a process for preparing a polymer, whereinthe process comprises: providing a reaction mixture comprising a portionof at least one polar monomer and at least one multivalent cation;adding a mixture comprising the remaining portion of the polar monomerto the reaction mixture; and polymerizing the monomer to form thepolymer. In certain embodiments, the reaction mixture in the providingstep comprises at least two molar equivalents or greater of the totalamount of polar monomer with respect to one molar equivalent ofmultivalent cation.

In another embodiment of the present invention, there is provided aprocess for preparing a polymer, wherein the process comprises:providing a reaction mixture comprising at least one polar monomer, atleast one multivalent cation, and optionally at least one ethylenicallyunsaturated monomer; providing a monomer mixture comprising at least onepolar monomer and optionally at least one ethylenically unsaturatedmonomer; adding the monomer mixture to the reaction mixture; andpolymerizing the monomer to form the polymer.

In a further embodiment of the present invention, there is provided aprocess for preparing a polymer, wherein the process comprises:providing a reaction mixture comprising at least one polar monomer, atleast one multivalent cation, and optionally at least one ethylenicallyunsaturated monomer wherein the at least one multivalent cation issoluble within a solvent; providing a monomer mixture comprising atleast one polar monomer; adding a portion of the monomer mixture to thereaction mixture to form a polymer seed; adding the remainder of themonomer mixture to the reaction mixture on a gradual basis; andpolymerizing the monomer to form the polymer.

These and other aspects of the invention will become more apparent fromthe following detailed description.

The present invention is directed to processes for improving thephysical properties of polymer compositions, preferably aqueous polymerlatex compositions, by promoting cross linked sites between portions ofthe negatively charged polar monomer and the positively charged cationcontained therein prior to and/or during polymerization. The presentpolymer compositions may advantageously exhibit an improved balance ofproperties in comparison to polymer compositions prepared by methods ofthe prior art. In particular, the polymer compositions of this inventionmay exhibit improved strength properties, preferably without incurringadditional processing steps after polymerization or without creatingdistinct inorganic phases within the composition. The present inventionalso provides methods for improving a variety of polymer compositions,preferably aqueous polymer compositions, prepared by emulsion, solution,suspension, solvent, bulk, or other polymerization methods, through theaddition of a multivalent cation and the staged addition of the polarmonomer. The combination of the polar monomer and the multivalent cationto form, for example, a complex, may be used at any point prior toand/or during the polymerization.

It has now been found that the addition of a cation, typically a metalcation, to form a complex with a polar monomer prior to the addition ofthe remainder of the polar monomer and the polymerization of themonomer, may desirably foster the attraction between the negativelycharged functional groups within the polar monomer and the multivalentcation. The enhanced attraction between the polar monomer and cationresults in a polymer latex with improved physical properties such asincreased tensile strength. Although the present invention is discussedwith respect to emulsion-based polymers or aqueous polymer latexdispersions, it is understood that the methods of the present inventionare suitable for a variety of polymerization methods such as, but notlimited to, solution or suspension polymerization techniques. Indeed,the present invention is suitable for any polymerization technique inwhich a partially or completely negatively charged monomer, oligomer, orstabilizer is attracted to the positive charge of the multivalent cationand may participate in the polymerization.

In certain embodiments of the present invention, the polymer is preparedvia an emulsion-based polymerization technique to form an aqueouspolymer latex dispersion. Any conventional emulsion polymerizationtechnique for preparing an aqueous dispersion of polymer latex particlesfrom ethylenically unsaturated monomers may be employed such as singleor multiple shot batch processes, and continuous processes. Thepreparation of polymeric latexes is discussed generally in R. G.Gilbert, Emulsion Polymerization: A Mechanistic Approach, AcademicPress, NY (1^(st) Edition, 1995) and El-Aasser, Emulsion Polymerizationand Emulsion Polymers, John Wiley and Sons, NY (1997). The preparationof acrylic polymeric latexes is described in, for example, EmulsionPolymerization of Acrylic Polymers, Bulletin, Rohm and Haas Company,Philadelphia. In some embodiments, two separate reaction mixtures suchas a first aqueous reaction mixture and a second aqueous reactionmixture or monomer mixture, may be prepared initially, followed by amulti-stage emulsion polymerization of the monomer within the reactionmixtures. While the present application discusses multi-stagepolymerization primarily in terms of two stages, it is understood thatmore than two stages of polymerization of the monomer is furtherenvisioned. The terms “stage”, “multi-stage”, and “core shell”, as usedherein, is intended to encompass their broadest possible meaning, suchas, for example, the meaning conveyed in U.S. Pat. Nos. 3,793,402,3,971,835, 5,534,594, and 5,599,854, which disclose various means forachieving “staged” and “multi-staged” and core shell polymers. The firstreaction mixture typically comprises a combination, complex, or mixtureof the multivalent cation source and a portion of the polar monomer,surfactant and/or emulsifier, and optionally one or more ethylenicallyunsaturated monomers, whereas the second reaction mixture comprises theremainder of the polar monomer and optionally one or more ethylenicallyunsaturated monomers. In alternative embodiments, the remainder of thepolar monomer may be added neat to the first aqueous reaction mixture.Depending upon the end use of the aqueous polymer latex dispersion, thepolar monomer in the first aqueous reaction mixture and the secondaqueous reaction mixture of monomer emulsion may be the same or maydiffer. The term “aqueous polymer latex dispersion” refers to a polymerlatex that further comprises an aqueous, or water phase.

The aqueous polymer latex dispersion contains polymerized units derivedfrom at least one type of ethylenically unsaturated monomer. The term“units derived from”, as used herein, refers to polymer molecules thatare synthesized according to known polymerization techniques wherein apolymer contains “units derived from” its constituent monomers.Preferably, the ethylenically unsaturated monomer is selected such thatthe polymerized units within the aqueous polymer latex dispersion arewater insoluble, i.e., have low or no water solubility.

The preparation of the monomer mixture typically involves the vigorousmixing of at least one ethylenically unsaturated monomer with water and,optionally, an emulsifier. In other embodiments of the present inventionthe monomer may be added “neat”, i.e., added without water. The amountsof monomer, water, and emulsifier in the monomer mixture may varydepending upon, for example, the particular monomer and/or emulsifierselected, the intended end-use, the polymerization technique, and thelike. In certain embodiments, the amount of monomer in the monomermixture is preferably in the range of from 25 to 100, preferably from 40to 90, and even more preferably from 60 to 80 weight percent. The amountof water in the monomer mixture, if aqueous based, is preferably in therange of from 0.1 to 75, more preferably from 10 to 60, and even morepreferably from 20 to 40 weight percent based on the total weight of theemulsified monomer mixture (e.g., monomers, emulsifier, and water). Theamount of emulsifier, if added, in the monomer mixture is preferably inthe range of from 0.01 to 10, preferably from 0.05 to 2, and even morepreferably from 0.1 to 1 weight percent.

The monomers which may be polymerized include any of the ethylenicallyunsaturated monomers commonly known in the art, such as those listed inThe Polymer Handbook, 3^(rd) Edition, Brandrup and Immergut, Eds., WileyInterscience, Chapter 2, (1989). Suitable ethylenically unsaturatedmonomers include, for example, the C₁-C₁₈ alkyl (meth)acrylate monomers(e.g., methyl-, ethyl-, propyl-, n-butyl-, sec-butyl-, tert-butyl,pentyl-, isobornyl-, hexyl-, heptyl-, n-octyl-, 2-ethylhexyl-, decyl-,undecyl-, dodecyl-, lauryl, cetyl, and stearyl-(meth)acrylate and thelike); vinyl aromatic monomers (e.g., styrene, alpha-methyl styrene,para-methyl styrene, chlorostyrene, vinyl toluene, dibromostyrene,tribromostyrene, vinyl naphthalene, isopropenyl naphthalene,divinylbenzene and the like); vinyl esters (e.g., vinyl acetate; vinylversatate; and the like); vinyl-unsaturated carboxylic acids monomers(e.g., methacrylic acid, acrylic acid, maleic acid, itaconic acid);nitrogen-containing vinyl unsaturated monomers (e.g., acrylonitrile,methacrylonitrile, and C₁-C₁₈ alkyl (meth)acrylamides, and the like);dienes (e.g., butadiene and isoprene); ethylene,hydroxyethyl(meth)acrylate, hydroxypropyl(meth)acrylate, and the like.The term “alkyl (meth)acrylate”, as used herein, refers to both estersof alkyl acrylate and alkyl methacrylate.

For the purposes of preparing aqueous polymer latex compositions havingdesirable resistance to weathering, it is preferred to use monomersselected from the class of alkyl(meth) acrylates. For the purposes ofproviding low cost and commercially available aqueous polymer latexdispersions, it is preferable that the ethylenically unsaturated monomerbe selected from the group consisting of C₁-C₁₈ alkyl methacrylate,C₁-C₁₈ alkyl acrylate, acrylic acid, methacrylic acid, butadiene,vinylaromatic monomers, and the like. For the purposes of using theaqueous polymer latex dispersions for preparing coatings and adhesives,it is preferable to use C₁-C₁₈ alkyl (meth)acrylate monomers; acrylicacid; methacrylic acid; itaconic acid; vinyl acetate; vinyl versatate;vinyl aromatic monomers, and the like. It may be even more preferable touse n-butyl acrylate, ethyl acrylate, butyl methacrylate, methylmethacrylate, styrene, butadiene, acrylic acid, and methacrylic acidmonomers for the purpose of providing aqueous polymer latex dispersionsin a variety of applications due to their relatively low cost andcommercial availability.

In certain embodiments, the monomer mixture in the first and/or thesecond aqueous reaction mixtures may be emulsified. In theseembodiments, suitable emulsifiers may include, but are not limited to,those conventionally used in emulsion polymerization, such as salts ofalkyl-, aryl-, aralkyl-, alkaryl- sulfates or sulfonates; alkyl-, aryl-,aralkyl-, alkaryl-poly(alkoxyalkyl) ethers; alkyl-, aryl-, aralkyl-,alkaryl- poly(alkoxyalkyl) sulfates; alkali salts of long-chain fattyacids such as potassium oleate, typically alkyl diphenyloxidedisulfonate; and the like. The preferred emulsifiers may include, forexample, dodecyl benzene sulfonate and dioctyl sulfosuccinate.Additional emulsifiers may include, for example, non-ionic surfactantssuch as ethyloxylated alcohols.

Where it is desirable to covalently crosslink the polymers and/or tograft link multiple stage polymers, crosslinkers and/or graftlinkers mayalso be included in the monomer mixture(s). The term “crosslinker”, asused herein, refers to multi-functional monomers capable of forming twoor more covalent bonds between polymer molecules of the same type. Theterm “graftlinker”, as used herein, refers to multi-functional monomerscapable of forming two or more covalent bonds between polymer moleculesof one type with polymer molecules of another type. Suitablecrosslinkers or graftlinkers include, for example, divinyl benzene,butylene glycol di(meth)acrylate, alkanepolyol-polyacrylates oralkanepolyol-polymethacrylates such as ethylene glycol di(meth)acrylate,oligoethylene glycol diacrylate, oligoethylene glycol dimeth-acrylate,trimethylol-propane diacrylate, trimethylolpropane dimeth-acrylate,trimethylol-propane triacrylate (“TMPTA”) or trimethylolpropanetrimethacrylate, and unsaturated carboxylic acid allyl esters such asallyl acrylate, diallyl maleate, and typically allyl methacrylate, andthe like.

At least one of the monomers within the reaction mixture is a polarmonomer. The term “polar monomer”, as used herein, describes a monomerwith a partially or completely negative charge. Examples of thesemonomers include, but are not limited to, monomers containing carboxylicacid, phosphate, or sulfate functional groups. Still further examples ofpolar monomers are monomers that include hydroxyl, ester, ether,aldehyde and ketone functional groups. Preferably, the polar monomer isa carboxylic acid containing monomer. The term “acid containingmonomer”, as used herein, refers to any ethylenically unsaturatedmonomer that contains one or more acid functional groups or functionalgroups that are capable of forming an acid, such as an anhydride, forexample, methacrylic anhydride, maleic anhydride, or itaconic anhydride.Examples of acid containing monomers include, for example, carboxylicacid bearing ethylenically unsaturated monomers such as acrylic acid(“AA”), methacrylic acid (“MAA”), itaconic acid (“IA”), maleic acid andfumaric acid; acryloxypropionic acid and (meth)acryloxypropionic acid;sulphonic acid-bearing monomers, such as styrene sulfonic acid, sodiumvinyl sulfonate, sulfoethyl acrylate, sulfoethyl methacrylate,ethylmethacrylate-2-sulphonic acid, or 2-acrylamido-2-methylpropanesulphonic acid; phosphoethylmethacrylate (“PEM”); the correspondingsalts of the acid containing monomer; or combinations thereof. In theseembodiments, the total amount of acid containing monomer within thesystem may range from 0.01 to 100 weight percent, preferably from 0.1 to20 weight percent, and even more preferably from 0.1 to 5 weightpercent.

In other embodiments of the present invention, the polar monomer relatesto polar oligomers or unsaturated oligomers, such as trimers, that havea partially or completely negative charge and which have one or morepoints of unsaturation, such as terminal unsaturation. In certain otherembodiments of the present invention, the polar monomer relates to lowmolecular weight polymeric stabilizers that may be soluble in base(i.e., contain many CO₂H groups and are alkali soluble). Somenon-limiting examples of these polar, polymeric stabilizers includeMOREZ™ 101 or TAMOL™ 731, both of which are manufactured by Rohm andHaas, Inc. of Philadelphia, Pa. In these embodiments, the amount ofpolar stabilizer within the system may range from 1 to 50 weightpercent, more preferably from 15 to 50 weight percent.

In certain preferred embodiments, the first aqueous reaction mixtureincludes a complex comprising a monomer mixture of at least one polarmonomer and the multivalent cation. Preferably, the polar monomer is anacid containing monomer. In these embodiments, a portion of the polarmonomer within the overall composition is added to the first aqueousreaction mixture containing the multivalent cation to form, for example,a complex between the monomer and the cation, and the remainder of thepolar monomer is added to the second aqueous reaction mixture or addedneat. The amount of polar monomer that is added to the first aqueousreaction mixture is at least two molar equivalents to one molarequivalent of multivalent cation within the reaction mixture. Inembodiments involving acid-containing monomers, it is believed that thisallows the acid functional groups to bond to the cations and remainthere during the polymerization process. This staged method of polarmonomer addition may advantageously result in an improvement in physicalproperties in comparison to the straight addition of all of the polarmonomer to the second aqueous reaction mixture or monomer emulsion.

In embodiments where the acid-containing monomer is staged, the amountof acid staged in the first aqueous reaction mixture containing themultivalent cation can range from greater than 0% to less than 100% ofthe total acid charged within the aqueous polymer latex dispersion. Thesecond aqueous reaction mixture, or the remaining portion of polarmonomer that is added to the first aqueous reaction mixture, may containfrom 0% to 100%, preferably 1% to 50%, more preferably 5% to 25%, andeven more preferably 5% to 15% of the remaining acid containing monomerwithin the aqueous polymer latex dispersion.

The optimal amount of acid containing monomer will vary by thecomposition of the reaction mixture and the acid type, however, theamount of acid containing monomer will generally be at a level which istwo times or greater than the molar amount of divalent (or highervalency) ions added to the first aqueous reaction mixture. In thisregard, the amount of polar monomer that is added to the system is in anamount sufficient to neutralize the charge of the multivalent cationwithin the system. The term “neutralize”, as used herein, refers tobalancing a positive charge with a negative charge. For example, theoptimal amount to neutralize the charge of the multivalent cationbetween an acid containing monomer and a divalent cation would includeat least two molar equivalents of the acid containing monomer to onemolar equivalent of the divalent cation. This may result in a complex oftwo acid groups to one divalent cation. Similarly, in the case of theaddition of trivalent cations, the amount of acid containing monomerrelative to the amount of trivalent cation would include at least two,preferably three, molar equivalents of the acid containing monomer toone molar equivalent of the trivalent cation. Thus, the optimal amountof acid containing monomer and cation within the complex may employ onlyas much acid containing monomer as necessary in the first aqueousreaction mixture to neutralize the charge of the acid containing monomerto the cation; the remaining amount of acid containing monomer withinthe second aqueous reaction mixture may then aid in stabilizing thegrowing polymer latex particles.

A cation, preferably a multivalent cation, more preferably at least onedivalent or trivalent cation, and even more preferably at least onedivalent or trivalent metal cation, is added to the first reactionmixture. The addition of the cation to the reaction mixture containing aportion of the polar monomer results, for example, in the formation ofan in situ complex within the reaction mixture. The cation is preferablysoluble, i.e., is present at a level such that all of the cation maydissolve in a solvent. In preferred embodiments, the solvent is waterand the cation is water soluble. The cation may preferably be added tothe reaction mixture in the form of a slurry or a solution. In certainembodiments of the present invention, the cation is added in the form ofa solution containing a metal salt comprising at least one divalentand/or trivalent cation. Preferably, the metal salt is dissolved inwater or other solvent. Examples of such metal salts include, but arenot limited to Ca(OH)₂, Mg(OH)₂, or Mg(SO₄). Further non-limitingexamples of metal salts, comprising divalent or trivalent cations, areprovided in U.S. Pat. No. 5,998,538. The selection of the cation isinfluenced by the final use of the polymer or polymer latex whereas theselection of the anion in the metal salt influences the solublity andlatex stability. For example, a halide anion, such as Cl, maydestabilize the polymeric latex. As mentioned previously, the cation ispresent in an amount sufficient, for example, to form a complex in-situwith a portion of the polar monomer in the reaction mixture toneutralize the cation. In certain embodiments of the present invention,the amount of the cation that is added to the reaction mixture rangesfrom 0.001 to 10 weight percent, more preferably from 0.001 to 5 weightpercent, and even more preferably from 0.1 to 1 weight percent, basedupon the dry weight of the monomer and the amount of polar monomerwithin the polymer or aqueous polymer latex dispersion.

The cation may be added to the reaction at any point during thepolymerization process to foster the attraction between the negativelycharged polar monomer and the cation within the system and improve thephysical properties of the polymer. Prior to the addition of the cation,the percentage of monomer that is polymerized is from 0 to 90%, morepreferably from 0 to 50%. Preferably, the cation may be added to thereaction prior to the polymerization of the monomer to form the polymeror before the polymerization step. This mode of addition typicallyresults in greater improvements in the physical properties of thepolymer compared with adding the cation after polymerization.

In the third step of one embodiment of the present invention, the firstand second aqueous reaction mixtures, or the reaction mixture and theremaining polar monomer, are multi-stage emulsion polymerized. Suchmulti-stage emulsion polymerization preferably involves the sequentialpolymerization of two or more monomer mixtures wherein the monomers ofthe first monomer mixture are polymerized to more than 80%, preferablymore than 90%, and even more preferably more than 95% degree ofconversion to form a polymer particle dispersion. This polymerization ispreferably followed by the polymerization of a second monomer mixturecontaining the remaining polar monomer in the presence of the polymerparticle dispersion to form additional polymers which may associate withthe polymer particles (e.g., polymer shells around or domains within thepolymer particles) and/or form additional polymer particles, such ascore shell polymers.

The emulsion polymerization step is typically carried out in a suitablereactor wherein the reactants (monomers, initiators, optionalemulsifiers, multivalent cation, and optional chain transfer agents) aresuitably combined, mixed, and reacted in an aqueous medium, and whereinheat may be transferred into, and away from, the reactor. The reactantsare preferably added slowly (gradually, as in a semi-batch process) overtime, continuously, or quickly as a “shot” (batchwise) into the reactor.Typically, the reactants are gradually added (“grad-add”) to thereactor.

In other embodiments of the present invention, the polymericcompositions of the present invention may be prepared through techniquesother than emulsion polymerization. For example, these compositions maybe polymerized via bulk polymerization techniques, i.e., polymerizationwithout added solvents or water. In other embodiments, solutionpolymerization techniques may be used if the heat of polymerization ofthe monomer or viscosity of the polymer is too high. Preferably, thepolymerization occurs in an aqueous medium but other mediums, orsolvents, may be used. However, some disadvantages with solutionpolymerization may be removal of the solvent at the completion of thereaction or chain transfer reactions with the solvent which may limitmolecular weight.

In other embodiments of the present invention, the monomer within thepolymer latex may be polymerized by suspension polymerization. In theseembodiments, the monomer is mechanically dispersed in a liquid mediumand is polymerized as droplets. The liquid medium is preferably water,however other media, such as perfluorocarbons, may also be used. Theaddition of one or more stabilizers to the suspension, along withmechanical agitation, aid in preventing agglomeration of the monomerdroplets. Further non-limiting examples of suspension polymerization areprovided in George Odian, Principles of Polymerization, 2^(nd) ed. JohnWiley and Sons, NY (1981), pp 287-288.

In further embodiments of the present invention, the polymer colloids ofthe present invention may be prepared via mini-emulsion polymerizationtechniques. The term “colloid” as used herein refers to particles havinga number average particle size range from 0.05 to 1 μm. The term“mini-emulsion polymerization”, as used herein, generally relates tomethods involving stable submicron oil-in-water dispersions in which themonomer droplets within the dispersion may range in size from 0.05 to 1μm. Further discussion of mini-emulsion polymerization techniques isprovided in “Mini-emulsion Polymerization” by E. D. Sudol et al.,Emulsion Polymerization and Emulsion Polymers, John Wiley and Sons, NY(1997), pp. 700-722. The references, Erdem et al., “Encapsulation ofInorganic Particles via Mini-emulsion Polymerization”, Proc. Am. Chem.Soc. (Div Polym Mater Sci Eng) 1999, 80, 583 and Erdem et al.,“Encapsulation of Inorganic Particles via Mini-emulsion Polymerization.III. Characterization of Encapsulation”, Journal of Polymer Science:Part A: Polymer Chemistry, Vol. 38, 4441-4450 (2000), provides someexemplary methods for mini-emulsion polymerization. The dispersion istypically obtained by shearing a system comprising oil, water,surfactant, and, optionally, a co-surfactant. Due to the small dropletsize of the aqueous dispersion, it is believed that the monomer dropletswithin the mini-emulsion may become the dominant site for particlenucleation.

The stability of the monomer droplets within the mini-emulsion may arisefrom the use of a stabilizer in conjunction with an optionalcostabilizer. The stabilizer may include, for example, any of thesurfactants mentioned herein. In embodiments where a costabilizer isused, the costabilizer is preferably a low molecular weight, waterinsoluble compound such as, for example, cetyl alcohol, hexane, orhexadecanol. The amount of surfactant that may be added to the mixtureis from 0.1% to 10%, preferably from 0.5% to 5%, and more preferablyfrom 1% to 4% by weight, based upon the weight of monomer within themixture. The amount of co-surfactant, if added, to the mixture is from0.1% to 15%, preferably from 1% to 10%, and more preferably from 2% to8% by weight, based upon the weight of monomer within the mixture.

Various initiator systems are known in the art of free radicalinitiation and may be used in the methods described herein. Theselection of the initiator system may vary depending upon thepolymerization technique used. A thermal initiator, such as, but notlimited to, a persulfate salt may be used. Alternatively, a free radicalredox initiator system may also be employed. Examples of such systemsinclude, for example, an oxidizing agent or oxidant such as apersulphate, azo, peroxide (e.g., hydrogen peroxide, t-butylhydroperoxide, t-amylhydroperoxide), and the like in combination with areducing agent or reductant such as sodium metabisulphite, sodiumbisulfite, sodium sulfoxylate formaldehyde, sodium dithionite,isoascorbic acid, sodium hydrosulphite, 2-hydroxy-2-sulfinatoaceticacid, 2-hydroxysulfonatoacectic acid, and the like. It is believed thatthe presence of non-ionic surfactants within the present invention mayact as a phase transfer catalyst and aid in the delivering themultivalent cation to the polar groups within the polar monomer.

The free-radical initiators which are typically used in the varioussteps of the process are those conventionally utilized in free-radicalredox polymerizations conducted in the temperature range from 10° C. to100° C., preferably from 20° C. to 95° C., and more preferably from 55°C. to 90° C. Temperatures higher than 100° C. are possible usingequipment that is designed for elevated pressures. In some embodimentsinvolving redox initiation, initiation temperatures are preferably keptbelow 85° C., more preferably below 55° C. In other embodimentsinvolving thermal initiation with persulfate salts, temperatures in therange 80° C. to 90° C. are used.

In one embodiment of the present invention, the monomers may be addedbatch-wise (“shot”) or fed continuously or gradually adding over timeinto the reactor. Continuous feeding by gradual addition of the aqueousreaction mixtures into the reactor over times from 0.5 to 18 hours,preferably from 1 to 12 hours, and even more preferably from 2 to 6hours, is useful for controlling reaction temperature.

Buffers may also be present in the reaction mixture during an emulsionpolymerization. Buffers are generally the salts of weak acids such as,but not limited to, sodium bicarbonate, sodium carbonate or sodiumacetate. The amount of buffer that may be present, if added, in thereaction mixture may range from 0.01 to 5 weight percent based upon thetotal monomer utilized in the polymerization. Generally lower levels ofa strong base, such as ammonia or sodium hydroxide, can also be used tocontrol the pH of the polymerization. These agents may be added at anytime either before, during, or after the polymerization step. Buffersmay be further used to control hydrolysis of certain monomers, influencethe extent of premature crosslinking during polymerization (as in thecase when N-methylolacrylamide monomer is employed), influence the rateof decomposition of initiators, and/or affect the extent of dissociationof carboxylate acid monomers and surfactants to control colloidalstability.

Optionally, at least one chain transfer agent may be incorporated duringpolymerization to control the molecular weight of the polymer. Examplesof chain transfer agents include, but are not limited to, mercaptans,polymercaptans, and polyhalogen compounds. Further non-limiting examplesof chain transfer agents include alkyl mercaptans such as ethylmercaptan, n-propyl mercaptan, n-butyl mercaptan, isobutyl mercaptan,t-butyl mercaptan, n-amyl mercaptan, isoamyl mercaptan, t-amylmercaptan, n-hexyl mercaptan, cyclohexyl mercaptan, n-octyl mercaptan,n-decyl mercaptan, n-dodecyl mercaptan; mercapto carboxylic acids andtheir esters, such as methyl mercaptopropionate and 3-mercaptopropionicacid; alcohols such as isopropanol, isobutanol, lauryl alcohol andt-octyl alcohol; and halogenated compounds such as carbon tetrachloride,tetrachloroethylene, and tricholoro-bromoethane. Generally from 0 to 10%by weight, based on the weight of the monomer mixture, can be used. Thepolymer molecular weight may also be controlled by other techniques,such as selecting the ratio of initiator to monomer.

A stabilizing surfactant may be added to the reaction mixture todiscourage the aggregation of polymeric latex particles. In general, thegrowing latex particles are stabilized during emulsion polymerization byone or more surfactants such as an anionic or nonionic surfactant, or amixture thereof. Examples of surfactants suitable for emulsionpolymerization are provided in McCutcheon's Detergents and Emulsifiers(MC Publishing Co., Glen Rock, N.J.), published annually. Otherstabilizing agents, such as protective colloids can be used.

The reaction mixture may be polymerized in the presence of a pre-formedpolymer dispersion (“seed” latex), for controlling the desired particlesize. Seeds are also typically used for controlling the structure and/ormorphology of the resulting polymer. The “seed” latex may comprise smallparticles, having a mean diameter less than 200 nm, preferably less than100 nm, and even more preferably less than 65 nm. Typical seed latexparticles may have a composition similar to, or different than, thecomposition of the monomers used in preparing the first stage of themultistage polymer latex or the first stage of a seeded single stagepolymer latex polymer. The pre-formed polymer dispersion may includepolymer particles of a rubbery material, and may be similar or differentin composition to the core polymer. The term “rubbery”, as used herein,denotes the thermodynamic state of a polymer above its glass transitiontemperature. Alternatively, the seeds may include hard non-rubberypolymer particles, (e.g., polystyrene or polymethyl methacrylate), whichmay be used for adjusting refractive index, as taught in Myers et al.,U.S. Pat. No. 3,971,835.

Another process of the present invention involves the gradual additionand polymerization of an aqueous dispersion containing at least onepolar monomer that has been neutralized by the addition of a cation toone or more emulsion polymer seeds. The emulsion polymer seeds may beformed in the same reactor vessel where the monomers are polymerized orprepared in a separate reactor vessel and subsequently introduced to thereactor vessel where the monomers are polymerized. In this process, theemulsion polymer seeds preferably have a particle diameter of 20 to 500nm, more preferably 30 to 400 nm, and even more preferably 40 to 300 nm.The emulsion polymer seeds are from 0.1 to 10%, preferably 0.5% to 8%,even more preferably 1% to 5% based on dry weight of the total polymerweight in said polymer latex dispersion. The aqueous dispersion in thisprocess contains 80 to 99.95%, preferably 85 to 99.9%, and even morepreferably from 90 to 99.9% based on dry weight of the total dry polymerweight in the polymer latex dispersion of at least one ethylenicallyunsaturated monomer. After polymerization of each stage, it is desirablethat at least 95%, preferably at least 97%, and even more preferably atleast 99% based on weight of the monomer is polymerized in a reactorbefore a subsequent polymerization stage is begun.

The aqueous polymer latex dispersions of the present invention may alsobe prepared utilizing inverse emulsion polymerization. The processesdescribed in, for example, U.S. Pat. Nos. 3,284,393, 3,826,771,4,745,154, and accompanying references therein, can be incorporate, forexample, a multivalent cation and polar monomer complex into the aqueousphase of these polymerizations when used to make an acid containingpolymer (high or low levels of acid). Inverse emulsion polymerizationmethods may yield high molecular weight polymers or copolymers based onthe water soluble monomers and mixtures comprised thereof. An aqueoussolution of these monomers may be dispersed in an oil phase by means ofa water in oil emulsifier and subsequently polymerized under freeradical forming conditions.

The aqueous polymer latex dispersions of the present invention may beuseful, for example, as coatings, polishes, sealants, caulks, adhesives,and as plastics additives. The coating compositions comprising aqueouspolymer latex dispersions may exhibit improved properties like block,print and dirt pick-up resistance, enhanced barrier properties, scrubresistance, toughness, sheer strength, and wear resistance. Suitableapplications for the coating compositions of the present invention mayinclude architectural coatings (particularly low VOC applications forsemi-gloss and gloss); factory applied coatings (metal and wood,thermoplastic and thermosetting); maintenance coatings (e.g., overmetal); automotive coatings; concrete roof tile coatings; elastomericroof coatings; elastomeric wall coatings; external insulating finishingsystems; and inks. The aqueous polymer latex dispersions of the presentinvention may be useful as additives, dispersants, alkali solubleresins, acid functional thickeners. It is further contemplated that theaqueous polymer latex dispersions, when provided as an additive to acoating application, may impart hardness. Yet further non-limitingexamples of applications for the aqueous polymer latex dispersions:polish; binders (such as binders for nonwovens, paper coatings, pigmentprinting, or ink jet); adhesives (such as pressure sensitive adhesives,flocking adhesives, or other water based adhesives); plastics additives;ion exchange resins; hair fixatives; caulks; and sealants. The aqueouspolymer latex dispersion may impart strength and toughness to theaforementioned applications. Further, polish compositions comprisingaqueous polymer latex dispersions may exhibit enhanced properties suchas solvent resistance and strippability. Additionally, pressuresensitive adhesive compositions comprising aqueous polymer latexdispersions may exhibit enhanced properties such as optical clarity andwater resistance.

In one embodiment of the present invention, the aqueous polymer latexdispersions are capable of forming films upon drying (e.g., coatings andadhesives). In this embodiment, it is preferred that the polymers of thepolymer latexes have a glass transition temperature in the range of from−80° C. to 50° C. Glass transition temperatures may be calculated byusing the Fox equation (see T. G. Fox, Bull. Am. Physics Soc., Vol. 1,Issue No. 3, page 123(1956)).

An additional embodiment of the present invention contemplates preparinga coating composition containing an aqueous polymer latex dispersion.The coating composition of this invention may include, for example,coating or paint compositions which may be described in the art asarchitectural coatings, maintenance coatings, factory-applied coatings,automotive coatings, elastomeric wall or roof coatings, exteriorinsulating finishing system coatings, paper or paperboard coatings,overprint varnishes, fabric coatings and backcoatings, leather coatings,cementitious roof tile coatings, and traffic paints. Alternatively, thecoating or paint compositions may be described as clear coatings, flatcoatings, satin coatings, semi-gloss coatings, gloss coatings, primers,textured coatings, and the like. In these embodiments, it is preferredthat the polymers of the polymer latexes have glass transitiontemperatures that range from 0° C. to 70° C.

The coating composition may further include pigments and/or fillers suchas, for example, titanium dioxide, iron oxide, zinc oxide, magnesiumsilicate, calcium carbonate, organic and inorganic colored pigments, andclay. Such pigmented coating compositions preferably contain from 3 to70% pigment on a volume basis, and more preferably from 15 to 60%titanium dioxide on a volume basis.

The coating compositions of the present invention may be prepared by avariety of techniques which are well known in the coatings art. Incertain embodiments, at least one pigment is well dispersed in anaqueous medium under high shear mixing, such as by a COWLES™ mixer or,alternatively, at least one predispersed pigment may be used. Then, theaqueous polymer latex dispersion is added to the aqueous pigment mixtureunder low shear stirring along with other coatings adjuvants, ifdesired. Alternatively, the aqueous polymer latex dispersion may beincluded in the optional pigment dispersion step. The coatingcomposition may also contain conventional coatings adjuvants such as,for example, tackifiers, emulsifiers, coalescing agents, plasticizers,buffers, neutralizers, thickeners or rheology modifiers, humectants,crosslinking agents including heat-, moisture-, light-, and otherchemical- or energy-curable agents, wetting agents, biocides,plasticizers, antifoaming agents, colorants, waxes, water repellants,slip or mar aids, anti-oxidants, and the like. The coating composition,in addition to the aqueous polymer latex dispersion described herein,may also contain at least one or more additional polymers. Theseadditional polymers are preferably emulsion polymers selected fromeither film-forming and non-film-forming emulsion polymers that includesolid or hollow polymeric pigments, and may be present at a level of0-200%, based on dry weight of the total dry polymer weight in thepolymer latex dispersion.

The solids content of the coating composition may be from 10% to about70% by volume. The viscosity of the coating composition may be from 0.05to 100 pascal-seconds (Pa.s), or 50 to 100,000 centipoise (cP), asmeasured using a Brookfield viscometer. The viscosity of the coatingcomposition may vary depending upon the method of coating application.

The coating composition may be applied by conventional applicationmethods such as, for example, brushing and spraying methods such as, forexample, roll coating, doctor-blade application, printing methods,air-atomized spray, air-assisted spray, airless spray, high volume lowpressure spray, air-assisted airless spray, air knife coating, trailingblade coating, curtain coating, and extrusion.

The coating composition may be applied to a substrate such as, forexample, paper or paperboard; consolidated wood products; glass;plastic; wood; metal; primed or previously painted surfaces; weatheredsurfaces; asphaltic substrates; ceramics; leather; and hydraulicsubstrates such as cement in “green” or cured form, concrete, gypsum,and stucco. The coating composition applied to the substrate istypically dried, or allowed to dry, at a temperature from 10° C. to 95°C.

In another embodiment of this invention, an adhesive compositioncontaining an aqueous polymer latex dispersion is provided. The variouscomponents, processes, and uses of the aforementioned coatingcompositions are preferably applicable to these polymer latex-containingadhesive compositions.

In another embodiment of this invention, caulking and sealantcompositions containing an aqueous polymer latex dispersion areprovided. The various components, processes, and uses of theaforementioned coating compositions are preferably applicable to thesepolymer latex-containing caulking and sealant compositions. In addition,caulking and sealant compositions preferably have a paste-like orgel-like consistency and preferably have higher viscosities than docoatings. Accordingly, caulks and sealants can be prepared using theaqueous polymer latex dispersions of the present invention according tothe general formulations known in the art of preparing caulks andsealants from emulsion polymers. In this embodiment, caulks and sealantscan be prepared by blending fillers with the aqueous polymer latexdispersions according to methods known in the art.

In some embodiments of this invention, the aqueous polymer latexdispersions desirably form films upon drying, with or without theaddition of plasticizers or coalescents (e.g., coatings and adhesives).In these embodiments, it is preferred that the polymers of the polymerlatexes have glass transition temperatures in the range of from −80° C.to 50° C.

In another embodiment of this invention, an adhesive compositioncontaining an aqueous polymer latex dispersion is contemplated. Theadhesive compositions may include, for example, those known in the artas pressure sensitive adhesives, laminating adhesives, packagingadhesives, hot melt adhesives, reactive adhesives, flocking adhesives,and flexible or rigid industrial adhesives. In these embodiments it ispreferred that the polymers of the polymer latexes have glass transitiontemperatures in the range of from −80° C. to 80° C. The adhesives aretypically prepared by admixing optional pigment and the optionaladjuvants listed herein above as coatings adjuvants. The adhesivecompositions are typically applied to substrates including plasticsubstrates such as film, sheet, and reinforced plastic composites; metalfoil; fabric; metal; glass; cementitious substrates; and wood or woodcomposites. Application to the substrates is typically effected onmachine by transfer roll coater, e.g., or by manual application devices.

In another embodiment of this invention, a caulk or sealant compositioncontaining an aqueous polymer latex dispersion is contemplated. In theseembodiments it is preferred that the polymers of the polymer latexeshave glass transition temperatures in the range of from −80° C. to 0° C.The caulk or sealant compositions are typically prepared by admixingpigment and such optional adjuvants listed hereinabove as coatingsadjuvants as are appropriate. The caulk and sealant compositions aretypically prepared at high solids content level such as 70 wt. % andabove in order to minimize shrinkage on drying and consequently, mayhave a gel-like or paste-like consistency. Caulk and sealantcompositions are typically applied to fill and/or seal junctions ofsubstrates including metal; glass; cementitious substrates; wood or woodcomposites; and combinations thereof and are typically allowed to dryunder ambient conditions.

In another embodiment of this invention, an ink composition containingan aqueous polymer latex dispersion is contemplated. The inkcompositions may include, for example, those known in the art asflexographic inks, gravure inks, ink jet inks, and pigment printingpastes. In these embodiments it is preferred that the polymers of thepolymer latexes have glass transition temperatures in the range of from−50° C. to 50° C. The inks are typically prepared by admixing optionalpigment, predispersed pigment, or dyes and the optional adjuvants listedherein above as coatings adjuvants. The ink compositions are typicallyapplied to substrates including plastic substrates such as film, sheet,and reinforced plastic composites; paper or paperboard; metal foil;fabric; metal; glass; cloth; and wood or wood composites. Application tothe substrates is typically effected on machine by flexographicblankets, gravure rolls, silk screens.

In a further aspect of the present invention, a digital imagingcomposition incorporating an aqueous polymer latex dispersion and/orpolymer latex particles is contemplated. The term “digital imaging” asused herein generally relates to compositions that allow thereproduction of an image onto a substrate. Suitable applications fordigital imaging compositions include toners for electrophotography suchas xerography or compositions for ink jet printers or similarapplications. The Tg and particle size for digital imaging compositionsvaries depending upon its method or system of use. Generally, digitalimaging compositions for ink jet applications may have a lower particlesize and Tg compared to the particle size and Tg for digital imagingcompositions for electrophotography applications. For example, typicalTg values for ink jet applications may range from 45° C. to 60° C.whereas Tg values for electrophotography applications may range from 55°C. to 85° C. Further, non-limiting variables such as viscosity, surfacetension, and pH of the digital imaging composition may also be adjustedbased upon the end use of the composition.

In another embodiment of this invention, a nonwoven fabric bindercontaining an aqueous polymer latex dispersion is contemplated. Thenonwoven binder compositions may include, for example, those known inthe art as binders for consumer and industrial nonwovens such as wipesand interlining, binders for insulating nonwovens such as fiberfill andfiberglass, and binders/strengthening agents for nonwovens and papersuch as oil filter paper. In these embodiments it is preferred that thepolymers of the polymer latexes have glass transition temperatures inthe range of from −60° C. to 50° C. The nonwoven fabric binders aretypically prepared by admixing optional pigment, and the optionaladjuvants listed herein above as coatings adjuvants, as appropriate. Thenonwoven fabric binder compositions are typically applied to substratesincluding nonwovens formed from cellulosic fibers such as paper andrayon; synthetic fibers such as polyester, aramid, and nylon; glassfibers and mixtures thereof. Application to the substrates is typicallyeffected on machine by saturation bath, roll coater, spray, or the like.

In another embodiment of this invention, a polish containing an aqueouspolymer latex dispersion is contemplated. The polish compositions mayinclude, for example, those known in the art as floor polishes,furniture polishes, and automobile polishes. In these embodiments it ispreferred that the polymers of the polymer latexes have glass transitiontemperatures in the range of from 0° C. to 50° C. The polishes aretypically prepared by admixing optional pigment, and the optionaladjuvants listed herein above as coatings adjuvants, as appropriate,particularly waxes. The polish compositions are typically applied tosubstrates including wood, vinyl or polyurethane flooring, ceramictiles, painted metal, and the like. Application to the substrates istypically effected by spray, roller, mop, or the like.

In another embodiment of this invention, a plastics additive containingan aqueous polymer latex dispersion is contemplated. The plasticsadditive compositions may include, for example, those known in the artas processing aids and impact modifiers. In these embodiments it ispreferred that the polymers of the polymer latexes have glass transitiontemperatures in the range of from −50° C. to 50° C. The plasticsadditives are typically prepared by admixing optional pigment, and theoptional adjuvants listed herein above as coatings adjuvants, asappropriate, and, typically, drying the composition to a powdered form.The plastics additives compositions are typically mixed with the plasticsuch as, for example, polyvinyl chloride, polymethyl methacrylate andpolypropylene, by milling or extrusion.

In another aspect of the present invention, the emulsion polymer of thepolymer latex may be prepared by a multistage emulsion polymerizationprocess, in which at least two stages differing in composition arepolymerized in sequential fashion. Such a process usually results in theformation of at least two mutually incompatible polymer compositions,thereby resulting in the formation of at least two phases within thepolymer particles. Such particles are composed of two or more phases ofvarious geometries such as, for example, core/shell or core/sheathparticles, core/shell particles with shell phases incompletelyencapsulating the core, core/shell particles with a multiplicity ofcores, and interpenetrating network particles. In all of these cases themajority of the surface area of the particle will be occupied by atleast one outer phase and the interior of the particle will be occupiedby at least one inner phase. Each of the stages of the multi-stagedemulsion polymer may contain the same monomers, surfactants, chaintransfer agents, etc. as disclosed herein-above for the emulsionpolymer. In the case of a multi-staged polymer particle the Tg for thepurpose of this invention is to be calculated by the Fox equation usingthe overall composition of the emulsion polymer without regard for thenumber of stages or phases therein. The polymerization techniques usedto prepare such multistage emulsion polymers are well known in the artsuch as, for example, U.S. Pat. Nos. 4,325,856; 4,654,397; and4,814,373.

In other aspects of the present invention, the emulsion polymer of thepolymer latex may be prepared by an emulsion polymerization processwhich is executed in such a manner to produce a bimodal or mutimodalparticle size distribution as is taught in U.S. Pat. Nos. 4,247,438;4,657,966; and 5,498,655, a bimodal or multimodal molecular weightdistribution as is taught in U.S. Pat. Nos. 4,501,845 and 5,990,228, ornon spherical particles such as, for example, rods as are taught in U.S.Pat. No. 5,369,163 and multilobal particles as are taught in U.S. Pat.No. 4,791,151.

In another aspect of the present invention, the emulsion polymer of thepolymer latex may be prepared by a process which produces particleswhich may function in a manner instead of or in addition to providingbinder functionality. Contemplated are emulsion polymers which functionas pigment dispersants or thickeners/rheology modifiers such asalkali-soluble, acid-soluble, and hydrophobically-modified emulsionpolymers.

In certain aspects of the present invention, the aqueous polymer latexdispersions may be used in polymer compositions incorporating highlevels of acid functionality. These polymer compositions are useful asadditives in water based systems as thickeners (see, for example, U.S.Pat. No. 4,421,902 and references therein), dispersants (see, forexample, U.S. Pat. Nos. 5,326,843 and 3,037,952 and references therein)and binders (see, for example, U.S. Pat. Nos. 5,326,843 and 4,876,313and references therein) as well as coatings, inks, adhesives and thelike. When the polymer latex compositions prepared in accordance withthe method of the present invention are incorporated into high acidpolymer compositions, the resultant polymer may increase in hardness.This imparts properties such as enhanced block resistance (i.e., thecoating will not stick to itself or other items) when used in a paintcomposition. Ink binders, that are comprised entirely or partially ofhigh acid polymers, will exhibit enhanced heat seal resistance (blockresistance at elevated temperature) and toughness when the polymer latexcompositions are added to the binder composition. In yet anotherembodiment utilizing high acid polymers, the polymer latex compositionsof the present invention may be used as dry powder polymer cementmodifiers (such as described in, for example, EP0654454 and referencestherein).

EXAMPLES Example 1

(0.18% Ca(OH)₂/MAA/Na₂CO₃ Addition Order)

A latex was prepared via the following method: An empty reactor kettlewas charged with 612.00 g deionized water and 5.08 g anionic surfactant(30% aqueous solution). The reaction mixture was heated to 85° C. andthen a multivalent ion slurry containing 1.84 g of Ca(OH)₂ in 5.00 g DIwater was added to the reaction mixture. Next, a quantity of 7.55 g ofmethacrylic acid (“MAA”) was then charged to the kettle followed by 3.10g sodium carbonate (foaming was observed). In a separate vessel, amonomer emulsion was prepared containing 426.60 g water, 36.90 g anionicsurfactant (30% aqueous solution), 662.00 g Butyl Acrylate (“BA”),342.70 g Methyl Methacrylate (“MMA”), and 7.55 g methacrylic acid(“MAA”). A 55.80 g quantity of the monomer emulsion was added to thereaction mixture to form a polymer seed. Then, a quantity of 4.03 gammonium persulfate dissolved in 28 g water was added to the reactionmixture to initiate polymerization. The monomer emulsion was fed intothe kettle such that a reactor temperature of 85° C. was maintained.After monomer feeds were completed, the batch was cooled to 65° C., andupon reaching 65° C. 5.58 g ferrous sulfate (0.15% aqueous) was added tothe reactor. Then, a 1.12 g quantity of 70% tert-butyl hydroperoxide in20.00 g of water was added along with a 0.56 g quantity of isoascorbicacid in 20.00 g water. The temperature was reduced to below 45° C. ThepH of the batch was raised to 7.5 using ammonium hydroxide (28% aqueous)and a bactericide (4.77 g Kathon LX (1.4% aqueous) with 6.20 g water)was added. The sample was filtered through a 100 mesh screen to removeany large pieces of coagulated material.

Example 2

(0.09% Ca(OH)₂/MAA/Na₂CO₃ Addition Order)

A latex was prepared in the same manner as Example 1 except that aweight percentage of 0.09% calcium hydroxide by weight of monomercontent was used.

Example 3

(0.05% Ca(OH)₂/MAA/Na₂CO₃ Addition Order)

A latex was prepared in the same manner as Example 1 except that aweight percentage of 0.05% calcium hydroxide by weight of monomercontent was used.

Example 4

(0.07% Mg(OH)₂/MAA/Na₂CO₃ Addition Order)

A latex was prepared in the same manner as Example 1 except that aweight percentage of 0.07% magnesium hydroxide (equimolar in divalention content with Example 2) by weight of monomer content was used.

Example 5

(0.04% Mg(OH)₂/MAA/Na₂CO₃ Addition Order)

A latex was prepared in the same manner as Example 1 except that aweight percentage of 0.04% magnesium hydroxide (equimolar in divalention content with Example 3) by weight of monomer content was used.

Example 6

(0.17% Mg(SO₄)•7H₂O/MAA/Na₂CO₃ Addition Order)

A latex was prepared in the same manner as Example 5 except that aweight percentage of 0.04% magnesium sulfate heptahydrate (equimolar indivalent ion content with Examples 3 and 5) by weight of monomer contentwas used.

Comparative Example 7

(0.18% Ca(OH)₂/Reduced MAA Stage/Na₂CO₃ Addition Order)

A latex was prepared in the same manner as Example 1 except that thepercentage of acid containing monomer, or MAA, that was charged to thereaction kettle in the beginning of the reaction was reduced from 50% to14%.

Comparative Example 8

(0/o Ca(OH)₂/MAA/Na₂CO₃ Addition Order)

A latex was prepared in the same manner as Example 1 except that nodivalent ion was charged and the and the percentage of acid containingmonomer charged to the kettle in the beginning of the reaction wasreduced from 50% to 0%.

Comparative Example 9

(0.18% Ca(OH)₂/MAA/Na₂CO₃ Addition Order)

A quantity of 0.18% calcium hydroxide by weight of monomer charged wasadded to the latex made in Comparative Example 8. This examplerepresents the prior approach of forming ionic crosslinks by bringingtogether an already formed polymer containing acid group side chainswith a divalent ion salt.

Tensile Strength Testing

The polymers of Examples 1 through 6 and Comparative Examples 7 through9 were made into sample films of unformulated coatings and tested forthe tensile properties of maximum tensile strength. The test data foreach film was collected on a Tinius Olsen Benchtop Universal TestingMachine (manufactured by Tinius Olsen Testing Machine Company, WillowGrove, Pa.). The sample films were pulled at a rate of 5.08 cm/min. Thetesting machine was calibrated for the film thickness, width, and weightof each sample film. The initial distance between the clamps holding thesample being tested is 2.54 cm. The tests were conducted in a controlledenvironment room with a temperature of 22° C. and a humidity level of50%. The tensile measurements for each film are provided in thefollowing Table I.

As the results in Table I illustrate, the addition of a multivalent ionslurry containing Ca or Mg improved the overall tensile properties ofthe polymer in comparison to polymers without the addition of themultivalent ion slurry or Example 8C. Higher tensile strengthmeasurements are also observed by staging the acid containing monomer.In some instances, such as in Example 1, the tensile strength of theresultant polymer is nearly 4 times that of the polymer without theaddition of the multivalent ion slurry or the staged acid containingmonomer. Further, having a higher percentage of the acid containingmonomer in the reaction kettle, or 50% MAA in Example 1 vs. 14% inExample 7C, prior to the addition of the monomer seed to the reactionkettle also results in increased tensile strength. Lastly, adding themultivalent ion slurry prior to polymerization of the monomer within thereaction vessel such as in Example 1, results in a higher tensilestrength polymer than adding the multivalent ion slurry afterpolymerization such as in Example 9C.

TABLE I Tensile Properties Versus Method of Cation and Acid AdditionDivalent Ion and Ex # Description Level Acid Staged¹ Tensile_(max) ² 1Pre-Comp 0.18% Ca(OH)₂ 50% MAA 351 psi 2 Pre-Comp 0.09% Ca(OH)₂ 50% MAA206 psi 3 Pre-Comp 0.05% Ca(OH)₂ 50% MAA 138 psi 4 Pre-Comp 0.09%Mg(OH)₂ 50% MAA 199 psi 5 Pre-Comp 0.05% Mg(OH)₂ 50% MAA 136 psi 6Pre-Comp 0.05% Mg(SO₄) 50% MAA 182 psi 7C Reduced MAA 0.18% Ca(OH)₂ 14%MAA 110 psi Stg. 8C Control None None  88 psi 9C Post-Add 0.18% Ca(OH)₂None  98 psi ¹Percent of total acid charge that is added just after thedivalent ion. Overall composition of samples is: 65.0 BA/33.5 MMA/1.5MAA ²Tensile_(max) values are +/− 5 psi.

I claim:
 1. A process for preparing a polymer, wherein the processcomprises the steps of: providing a reaction mixture comprising at leastone polar monomer, at least one water-soluble multivalent cation, andoptionally at least one ethylenically unsaturated monomer; providing amonomer mixture comprising at least one polar monomer and optionally atleast one ethylenically unsaturated monomer; adding a portion of themonomer mixture to the reaction mixture to form a polymer seed; addingthe remainder of the monomer mixture to the reaction mixture on agradual basis; and emulsion polymerizing the monomer mixture to form thepolymer.
 2. The process of claim 1 wherein the reaction mixture in theproviding step comprises at least 25% by weight of the total amount ofpolar monomer.
 3. The process of claim 2 wherein the reaction mixture inthe providing step comprises at least 50% by weight of the total amountof polar monomer.
 4. The process of claim 1 wherein the amount of thepolar monomer relative to the amount of the multivalent cation, in molarequivalents, is at least two to one.
 5. The process of claim 4 whereinthe amount of the polar monomer relative to the amount of themultivalent cation is sufficient to neutralize the ionic charge of themultivalent cation.
 6. The process of claim 1 wherein said polar monomercomprises an acid containing monomer.
 7. The process of claim 6 whereinsaid acid containing monomer is selected from the group consisting ofmethacrylic anhydride, acrylic acid, methacrylic acid, itaconic acid,maleic acid, fumaric acid, acryloxypropionic acid,(meth)acryloxypropionic acid, styrene sulfonic acid,ethylmethacrylate-2-sulphonic acid, 2-acrylamido-2-methylpropanesulphonic acid; phosphoethylmethacrylate; the corresponding salts of theacid containing monomer, and combinations thereof.
 8. The process ofclaim 1 wherein said polar monomer comprises a low molecular weight,polymeric stabilizer.
 9. The process of claim 1 wherein the multivalentcation comprises at least one cation selected from the group consistingof divalent cations and trivalent cations.
 10. The process of claim 1wherein the reaction mixture further comprises at least oneethylenically unsaturated monomer.
 11. The process of claim 10 whereinthe at least one ethylenically unsaturated monomer is selected from thegroup consisting of: C₁-C₁₈ alkyl (meth)acrylate, 2-ethylhexyl(meth)acrylate, isobornyl (meth)acrylate, lauryl (meth)acrylate, allyl(meth)acrylate, stearyl (meth)acrylate, acrylic acid, itaconic acid,methacrylic acid, butadiene, vinyl acetate, vinyl versatate, styrene,vinyl aromatic monomers, divinylbenzene, divinylpyridine,divinyltoluene, diallyl phthalate, butylene glycol di(meth)acrylate,ethylene glycol di(meth)acrylate, divinylxylene, divinylethylbenzene,divinylsulfone, divinylketone, divinylsulfide, diallyl maleate, diallylfumarate, diallyl succinate, diallyl carbonate, diallyl malonate,diallyl oxalate, diallyl adipate, diallyl sebacate, divinyl sebacate,diallyl tartrate, diallyl silicate, triallyl tricarballylate, triallylaconitate, triallyl citrate, triallyl phosphate, N,N-methylenedimethacrylamide, N,N-methylene dimethacrylamide,N,N-ethylenediacrylamide, trivinylbenzene, and the polyvinyl ethers ofglycol, glycerol, pentaerythritol, resorcinol, monothio and dithioderivatives of glycols, and combinations thereof.
 12. The process ofclaim 1 wherein said emulsion polymerization comprises inverse emulsionpolymerization.
 13. The process of claim 1 wherein the glass transitiontemperature of said polymer is in the range of from −80° C. to 50° C.14. The process according to claim 1, wherein the glass transitiontemperature of said polymer is in the range of from −80° C. to 140° C.